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Some Best Practices for Metal Finishing

Date: 10-09-2018

Grinding with Klingspor

Observing the right methods in surface cleaning and finishing of welded materials enables you to deliver excellent products. There are several levels of surface finishing requirements, and these are dependent on specific industry demands.

Here are some best practices for surface finishing.

Learn and differentiate finishing methods

Metal finishing covers a wide range of techniques that are dependent on the tools used, how the metal will be used and where it will be installed.

Coarse grinding involves removing excess metal at a rapid pace. Grinding wheels should not be forced and should be used at the proper angle. Allowing wheels to ride on the work at the right speed, angle and consistency will result in efficient cutting. The recommended grinding angle is typically found on the product label. Always start using a grinding wheel by gently touching the work piece and pulling back, instead of pushing down. Starting with the pull back motion enables the welder to hold the wheel flatter and lighter on the surface.

Polishing is the process of attaining smoothness on metals and utilises grits of 80 and finer. If the product requires polishing, start with the finest possible grit to lessen finishing steps. Non-woven products are especially useful in the final steps of the finish.

Etching is achieved through glass bead and sandblasting. The metal must be clean and free from carbon steel contamination; otherwise, the end product would bear stains.

Ensure you have the right equipment

Choosing the right products for surface finishing applications is important in meeting application requirements. They can enhance your productivity while reducing cross-contamination that could lead to rework.

Understanding the requirements of the application is key to selecting the right equipment for the job. Doing a careful study of the base material, and the eventual use of the finished product, are also part of the process.

It is very important to use the correct grinder and its backing pad where required. This can make a huge difference to the outcome of the performance of the abrasive. 

Good quality abrasive tools also will come with directions or pictograms explaining what personal protection equipment should be used. Safety instructions should always be followed... they are there for a reason!

Here are common categories for metalworking surface preparation and finishing:

  • Abrasive Cutting Products – These tools can remove a lot of the surface material but typically leave a rougher finish compared to other finishing tools.
  • Coated Abrasive Products produce different surface finishes dependent on several factors, including the grit type and size. Flap discs, which fall under this category, combine the aggression of a grinding wheel and the finishing qualities of a resin fibre disc.
  • Non-Woven Abrasive Products typically include surface conditioning discs, blending discs and convolute wheels. These tools are made of fibres that include abrasive grains. They are also used for decorative finishes because they leave a finer surface finish.

Our product range includes a number of high-quality products from Klingspor Abrasives.

Colours of abrasive belts and discs and what do the colours mean?

Most manufacturers of abrasives use dyes to add colour to their products. In general the colours represent the following grains; Brown - Aluminium oxide, suitable for steel and non-ferrous metals. Blue - Zirconia, suitable for stainless steel.Green - Zirconia but with a coating to help reduce heat, suitable for thin walled stainless.

Can I achieve a mirror finish with just abrasives?

Non-woven abrasives will leave a good uniform scratch-pattern when used properly and abrasives are an important step to achieving mirror finish but you will need to polish the steel using polishing buffs and compounds to achieve a true mirror finish.

Our special offer at Alphaweld

Select Klingspor cutting disks will be on sale from 01/09/18 to 30/09/18. Visit our Current Specials page for more information.   

About Alphaweld Supply Group

We are welding equipment suppliers with more than a decade of experience in sourcing market-leading supplies and equipment. Contact us on 6108 9456 8000 for all enquiries.